Vibration stabilizing guide wheel

ABSTRACT

A fixed guide wheel that when coupled to a saw blade or a grinding wheel provides a sawing or grinding system that will control the exact depth at which the tools are allowed to perform. The guide wheel also rolls along the top surface of the work piece pushing down on it (pinching it) while the cutting or grinding process is occurring. The guide wheel has a central bearing that carries the saw blade or grinding wheel across the surface of the stone keeping the tools centered and balanced with each other. The guide wheel is made from a rigid, low-density material that absorbs vibration that would normally transfer from the grinding wheel to the material being cut.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

BACKGROUND

1. Field of Invention

This invention is a guide wheel that allows consistent vibration freegrinding when used with electroplated diamond grinding wheels; segmenteddiamond grinding wheels and diamond rimmed saw blades.

2. Description of Prior Art

For years, the industry has been using diamond tools to cut andfabricate ceramic tile and natural stone products. These tools aretypically used with a portable tile saw that can easily be set up andused on location. All tile saws with a standard arbor size can use aprofile wheel to create different profiles or shapes on the edge of thematerial being installed. The profile wheels are made in severaldifferent shapes and sizes. Since the introduction of profile wheels,people have come to realize that even though it is a good idea, theircapabilities are extremely limited. The first problem is that allportable tile saws share the same basic design. They have a weldedsquare tube frame that has a support post located in the back left sideof the machine. This support post holds the upper saw assembly in placewhile the machine is operating. When a saw blade or a profile wheel isbeing used, the entire upper saw assembly would rise up slightly uponcontact with the material and then go down as material is removed. Thismovement carries the profile wheel up and down creating a rough,inconsistent edge. If it does not grind enough, the material needs to befurther worked. In either case, the machine is constantly moving up anddown creating an impossible situation for precision grinding.

The second problem is stone tiles will vary in thickness from one box toanother throughout the job. Individual tiles can actually taper inthickness.

The third problem is that natural stone has inconsistencies in materialhardness. This allows the profile wheel to remove more material in asoft area and rise up and over a harder one. Even small pieces of debrisunder a tile being profiled can cause over grind situations. This forcesthe installer to cut that particular tile into a smaller size to be usedelsewhere on the job. It should be appreciated that every natural stonetile is unique and if one is damaged due to over grinding, it cannot bereadily replaced.

When a saw blade is being used under these up and down conditions, itcauses excessive chipping along the top edge of the tile. This larger ordeeper chipping forces the fabricator to grind and polish a deeper bevelon the tile's edge. This ultimately affects the width of the grout line,especially if tiles are being installed very close together. Thisprocess is called “little or no grout” installation.

Working with stone is a very slow process. Most material is so hard,only diamonds can be used to remove the material with consistentaccuracy. The initial cut or profile grind must be accurate because thepolishing process that follows wan not designed to remove materialreadily. The polishing process was designed to remove surface scratchesand bring the stone to a final polish.

SUMMARY

The invention is a guide wheel that is preferably machined from acetate(delrin) and can be used with any diamond grinding wheel or diamond sawblade. When using the guide wheel with a grinding wheel, the size of theguide wheel is determined by the exact point at which the grindingwheel's shape should stop grinding. This eliminates the possibility ofover grinding and creates a point from where all shapes can beconsistently duplicated. When using the guide wheel with a diamondrimmed saw blade, the size of the guide wheel is determined by twothings; the diameter of the saw blade and the thickness of the materialbeing cut. An eight-inch saw blade with a seven-inch guide wheel willhave half of an inch of cutting depth. The guide wheel has an alignmentgroove located on its outside edge. This groove is used by the operatorto quickly set the grinding wheel slightly below the top surface of thestone. The guide wheel has a center cavity that holds a heavy-dutyroller bearing with two rubber seals. A stainless steel threaded insertis pressed into the center of the bearing. This insert replaces the tilesaw's standard arbor nut. When tightened, the threaded insert now holdsthe profile wheel or the saw blade into place. Now, with the machine on,the center bearing can turn and the guide wheel does not turn due to asmall amount of friction applied between the face of the guide wheel andthe flat inside surface of the tile saw's blade guard assembly. Thefriction is controlled by simply adjusting the wing nut that was used tomount the blade guard to the tile saw.

DESCRIPTION

FIG. 2 is a cross section of a fully assembled guide wheel. Stainlesssteel threaded insert (13) is press fit into bearing (12). Threadedinsert (13) extends through bearing (12) ⅛^(th) of an inch and lock ring(11) is press fit onto end of threaded insert (13). Once this is done,entire assembly press fits into center cavity of guide wheel (10). Then,internal snap ring (14) is installed. Note: Bearing (12) must makecontact with guide wheel beating seat (19) to ensure proper clearancefor snap ring (14).

FIG. 4 shows an adjustable wing nut (27) connected to mount bolt (30).This bolt assembly connects the blade guard (26) to the tile saw that isbeing used.

FIG. 4 shows blade guard contact area (16) making contact with theinside of the tile saw blade guard (26). FIG. 4 shows clearance (23)between inside of blade guard (26) and the face of threaded insert (13).FIG. 4 shows alignment groove (15) making contact with the top outsidecorner of tile material (25). FIG. 3 shows guide wheels tile contactsurface area (17) making full contact with the tile material (25). FIG.3 shows zero point (30). FIG. 3 shows profile wheel clearance (24) andclearance (20).

Note:

Clearance 20 0.035-0.040

Clearance 24 0.0125-0.130

Alignment groove 15 0.125×0.125

Description of Stainless Steel Threaded Insert (13)

FIG. 1—Threaded insert (13) has internal threads (18) that are tappedthrough. Internal threads (18) are the same size as the tile saw arbornut. Shoulder flange (22) seats up against bearing (12) to ensure properalignment. Wrench flats (22) are machined into face of threaded insert(13).

FIG. 2—Shows necessary clearance (23) between threaded insert (13) andblade guard contact area (16). REFERENCE NUMERALS IN DRAWINGS Guidewheel 10 Lock ring 11 Bearing 12 Stainless steel threaded insert 13Stainless steel internal snap ring 14 Alignment groove 15 Blade guardcontact area 16 Guide wheels tile contact surface 17 Internal threadsthru 18 Guide wheel bearing seat 19 Clearance area .035-.040 20 Wrenchflats 21 Shoulder flange 22 Clearance 23 Profile wheel clearance 24 Tilematerial 25 Blade guard 26 Wing nut 27 Waterfeed tubes 28 Profile wheel29 Mount bolt 30 Saw blade 31 Blade shaft 32 Extension arm 33

OPERATION

In operation, one could install the system on a standard portable tilesaw. First, remove the wing nut (27) and the mount bolt (30) in FIG. 4.Then the blade guard (26) can be removed and set aside. If necessary,remove stock arbor nut, blade flange and saw blade from machine and setaside. Install the profile wheel (29) as seen in FIG. 3 onto the machineshaft and thread on the guide wheel (10) until it tightens up againstthe profile wheel (29) in FIG. 3. Reinstall blade guard assembly (26) inFIG. 4 and mount bolt (30) and wing nut (27) in FIG. 4. Adjust wing nut(27) until inside of blade guard (26) applies enough force to keep theguide wheel (10) from turning easily. Do not over tighten as this willlock up the guide wheel (10) and cause it to slide across tile material(25). The guide wheel (10) is designed to roll across tile material (25)when in use but the guide wheel (10) should not turn unless there istile material (25) under it forcing it to turn. Next, adjust the machinedown into position until the alignment groove (15) fits into the topcorner of tile material (25) in FIG. 4. Tighten all adjustments so thatthe machine cannot move from this position. Guide wheel (10) and theprofile wheel are now adjusted ⅛^(th) inch below the top surface of thetile material (25) in FIG. 4.

Move the tile material (25) into position for profiling as in FIG. 3.Turn on the tile saw and check the guide wheel (10) FIG. 4 and make surethat guide wheel (10) is not turning. If it is, turn off the machine andtighten wing nut (27) in FIG. 4 until the inside of the blade guard (26)is applying enough friction against the face of the guide wheel (10) tokeep it from turning when the machine is operating. By adjusting profilewheel (29) and guide wheel (10) slightly below the surface of tilematerial (25) in FIG. 4, we create a situation where the tile saw willgo ahead and raise up when it contacts tile material (25) in FIG. 3.Because the guide wheel (10) allows us to lock in the grinding heightwell below the tip surface of tile material (25), we can take advantageof a downward force created when the tile material (25) is rolled underthe grinding wheel. This downward energy forces the profile wheel (29)to quickly remove the unwanted material faster with less passes. Guidewheel (10) is also applying a downward force on the edge of tilematerial (25). This downward force keeps the edge of tile material (25)from vibrating during the grinding process. While all of this ishappening, the Delrin or acetate guide wheel (25) is absorbing vibrationcreated by the grinding or sawing process. The acetate also protects thetile material (25) surface from scratches if the blade guard assembly isadjusted too tight (which causes the guide wheel to lock up and slideacross the surface of the stone).

Note: When using a profile wheel (29) to remove material as seen in FIG.3, the profile wheel (29) applies a force that wants to push tilematerial (25) out of position. For this reason, I designed an extensionarm (23) in FIG. 5.

A fixed wheel that stabilizes and absorbs vibration and controls depthof cut when coupled to a saw blade or grinding wheel comprising:

-   -   (a) fixed wheel of pre-determined size preferably made from a        rigid low density self lubricating material    -   (b) a bearing centrally mounted in said fixed wheel which will        able said fixed wheel to slowly rotate or be held stationary        regardless of said central bearings internal speed of rotation    -   (c) said central bearings internal bore with a fastener provides        means to couple said fixed wheel to any saw blade or grinding        wheel    -   (d) said fixed wheel with a said pre-determined diameter coupled        to said saw blade or said grinding wheel with a said        pre-determined diameter creates an exact contact point between        said fixed wheel diameter and the optimal depth of cut of said        saw blade or said grinding wheel    -   (e) position said fixed wheel coupled to said grinding wheel in        a vertical    -   (f) providing a flat piece of hard rigid material and placing it        onto a carriage that will carry said material directly under and        in line with said coupled fixed wheel grinding wheel    -   (g) position said fixed wheel's diameter slightly below said        material's surface height and lock said coupled fixed wheel        grinding wheel into place whereby as said material passes under        and through said coupled fixed wheel grinding wheel said fixed        wheel pushes down on said material holding said material as said        fixed wheel rolls across flat surface of said material said        fixed wheel's central bearing centers said grinding wheel's        rotation while said fixed wheel's low density material absorbs        rotation.

1. A method comprising: for a profile wheel fixedly mounted to a shaftand a guide wheel rotatably mounted to the shaft, the guide wheel havinga face and a contact surface, applying a first friction to the face ofthe guide wheel through a first force, the first friction sufficient toprevent the guide wheel from turning when the shaft is turning andwithout the contact surface of the guide wheel contacting a firstsurface; and while still applying the first friction, applying a secondforce through the shaft to the guide wheel toward the first surface toforce the guide wheel to rotate as the guide wheel is moved across thefirst surface as the contact surface of the guide wheel is contactingthe first surface.
 2. The method of claim 1 wherein the second force isapplied through the shaft by first, positioning the shaft in a firstposition when the contact surface of the guide wheel is free fromcontacting the first surface and by second, moving the first surface tocontact a portion of the contact surface of the guide wheel to move theshaft from the first position to a second position and to cause thesecond force to be applied to the shaft.
 3. The method of claim 2wherein the first position of the shaft is below the first surface andthe second position of the shaft is above the first surface.
 4. Themethod of claim 2 wherein a portion of the guide wheel other than thecontact surface of the guide wheel contacts the first surface when theshaft is positioned in the first position.
 5. The method of claim 1wherein the first friction is applied by contact with an acetatematerial.
 6. The method of claim 1 wherein the first friction is appliedby contact with a Delrin material.
 7. The method of claim 1 wherein thefirst friction is applied by contact of a blade guard on to the face ofthe guide wheel.
 8. A method comprising: for a profile wheel fixedlymounted to a shaft and a guide wheel rotatably mounted to the shaft, theguide wheel having a face and a contact surface, applying a second forcethrough the shaft to the guide wheel toward a first surface; anddecreasing a first friction to the face of the guide wheel throughdecreasing a first force until the first friction is sufficiently smallto allow the guide wheel to rotate as the guide wheel is moved acrossthe first surface as the contact surface of the guide wheel iscontacting the first surface.
 9. The method of claim 8 wherein thesecond force is applied through the shaft by first, positioning theshaft in a first position when the contact surface of the guide wheel isfree from contacting the first surface and by second, moving the firstsurface to contact a portion of the contact surface of the guide wheelto move the shaft from the first position to a second position and tocause the second force to be applied to the shaft.
 10. The method ofclaim 9 wherein the first position of the shaft is below the firstsurface and the second position of the shaft is above the first surface.11. The method of claim 9 wherein a portion of the guide wheel otherthan the contact surface of the guide wheel contacts the first surfacewhen the shaft is positioned in the first position.
 12. The method ofclaim 8 wherein the first friction is applied by contact with an acetatematerial.
 13. The method of claim 8 wherein the first friction isapplied by contact with a Delrin material.
 14. The method of claim 8wherein the first friction is applied by contact of a blade guard on tothe face of the guide wheel.
 15. A system comprising: for a profilewheel fixedly mounted to a shaft and a guide wheel rotatably mounted tothe shaft, the guide wheel having a face and a contact surface, meansfor applying a first friction to the face of the guide wheel through afirst force, the first friction sufficient to prevent the guide wheelfrom turning when the shaft is turning and without the contact surfaceof the guide wheel contacting a first surface; and while still applyingthe first friction, means for applying a second force through the shaftto the guide wheel toward the first surface to force the guide wheel torotate as the guide wheel is moved across the first surface as thecontact surface of the guide wheel is contacting the first surface. 16.The system of claim 15 wherein the second force is applied through theshaft by first, means for positioning the shaft in a first position whenthe contact surface of the guide wheel is free from contacting the firstsurface and by second, means for moving the first surface to contact aportion of the contact surface of the guide wheel to move the shaft fromthe first position to a second position and to cause the second force tobe applied to the shaft.
 17. The system of claim 16 including means forthe first position of the shaft to be below the first surface and meansfor the second position of the shaft to be above the first surface. 18.The system of claim 16 including means for a portion of the guide wheelother than the contact surface of the guide wheel to contact the firstsurface when the shaft is positioned in the first position.
 19. Thesystem of claim 15 including means for applying the first friction withan acetate material.
 20. The system of claim 15 including means forapplying the first friction with a Delrin material.
 21. The system ofclaim 15 including means for applying the first friction.
 22. A systemcomprising: for a profile wheel fixedly mounted to a shaft and a guidewheel rotatably mounted to the shaft, the guide wheel having a face anda contact surface, means for applying a second force through the shaftto the guide wheel toward a first surface; and means for decreasing afirst friction to the face of the guide wheel through decreasing a firstforce until the first friction is sufficiently small to allow the guidewheel to rotate as the guide wheel is moved across the first surface asthe contact surface of the guide wheel is contacting the first surface.23. The system of claim 22 wherein the second force is applied throughthe shaft by first, means for positioning the shaft in a first positionwhen the contact surface of the guide wheel is free from contacting thefirst surface and by second, means for moving the first surface tocontact a portion of the contact surface of the guide wheel to move theshaft from the first position to a second position and to cause thesecond force to be applied to the shaft.
 24. The system of claim 23including means for the first position of the shaft to be below thefirst surface and means for the second position of the shaft to be abovethe first surface.
 25. The system of claim 23 including means for aportion of the guide wheel other than the contact surface of the guidewheel to contact the first surface when the shaft is positioned in thefirst position.
 26. The system of claim 22 including means for applyingthe first friction with an acetate material.
 27. The method of claim 22including means for applying the first friction with a Delrin material.28. The method of claim 22 including means for applying the firstfrictionl.